Fabrication of ZAMAK 2 alloys by powder metallurgy process

Abstract

Parts with aluminum and zinc alloys mostly are produced by casting techniques. However, low production cost and lack of need for machining makes it necessary to produce ZAMAK alloys using a powder metallurgy method. Also, the production of ZAMAK alloys using a powder metallurgy method can be considered as a modern technique competitive to the gravity and die-casting techniques, due to its capability to produce parts with near-net shape and dimensions, self-lubrication, and sound-damping characteristics caused by the residual porosity deliberating left in these parts and the economics of the overall process. In this way, we study the production of ZAMAK 2 that has the maximum ultimate tensile strength among the ZAMAK alloys using a powder metallurgy technique. Mechanical methods were used to produce the powder, and the high-grade zinc powder was produced in three meshes. The resulting powder was mixed with powdered aluminum, copper, and magnesium. The final powder is ready to press now. The plots were pressed at three pressure rates: 500, 400, and 350 MPa. The components at temperatures 375, 260, and 160 °C were sintered that led to the production of 27 samples for investigation. The density, tensile strength, and hardness of generated samples were studied and compared to each other. The conditions that lead to produce the maximum hardness, maximum tensile strength, and maximum density were investigated.